SAHR CYPRIAN FILLIE

JOB REPORT
WEEK 0NE (4/08/2020-7/08/2020)
Work Experiences
Day 1 (04/08/2020)
Job number 1
Customer: UNICEF

Address: New England

Job type: Service

Job details: changing of oil, changing of filters including oil, fuel and air filter and cleaning of the
generator set.

Generator Power Rating: 200 KVA

Generator Make: Ghaddar Machinery

Engine Make: perkiness

Job Number 2
Customer: German Embassy

Address: Hill Cut

Job Type: service (on two generators)

Job details: changing of oil, changing fuel filter, oil filter, and air filter and cleaning of generator set

Generator sizes: 20 KVA each

Generator Make: Perkins

Engine Make: Perkins

Job Number 3
Customer: Law School

Address: New England

Job type: call out

Job detail: we removed a broken locker from the left side door

Generator Power Rating: 20 KVA

Generator Make: Perkins

Engine Make: Perkins

Day 2 (05/08/2020)

Job number 1
Customer: Ibrahim Anta

Address: Sani Abacha Street

Job Type: Service/Repair/Installation

Job Detail: changing of fuel filter, uninstallation of an old 24v DC alternator and installation of a new
one, cleaning of the generator set and uninstallation of a battery. There were two generators that we
worked on and all of the above works were done on the bigger generator. On the smaller generator a
subcontractor repaired its leaking radiator, refilled the radiator with coolant and we cleaned the
generator set.

Generator Power Rating: 60KVA and 20KVA

Generator Make: Ghaddar Machinery

Engine Make: Perkins

Job Number 2
Customer: Charms Beach Hotel

Address: Aberdeen beach

Job Type: Service

Job Details: changing of oil, changing of oil filter, fuel filter and air filter and cleaning of generator set

Generator power Rating: 60 KVA

Generator Make:

Engine Make: Lovol

Job Number 3
Customer: Sky K

Address: Kanneh drive, off Wilkinson road

Job type: service

Job detail: changing of oil, changing of oil filter, fuel filter and air filter and cleaning of generator set

Generator Power Rating: 20 KVA

Generator Make: Ghaddar Machinery

Engine Make: Ghaddar Machinery

Day 3 (06/08/2020)
Job Number 1
Customer: Skai Kay

Address: Goderich

Job Type: Service

Job detail: changing of oil, changing oil filter and air filter, cleaning of generator set, checking of water
level, belt tensioning, tightening of power cable connecting screws and greasing them to both remove
and prevent rust.

Generator Power Rating: 20 KVA

Generator Make: Leega

Engine Make: Perkins

Job Number 2
Customer: Law School

Address: Special Court, New England

Job Type: Installation

Job Details: replacement of a broken locker that was removed from the left side door with a new one

Generator Power Rating: 20 KVA

Generator Make: Perkins

Engine Make: Perkins

Job Number 3
Customer: Ibrahim Anta

Address: Sani Abacha Street

Job type: Installation

Job Details: reinstallation of the old 24V DC alternator that was formally replaced with a new one

Generator Power Rating: 60 KVA

Generator Make: Ghaddar

Engine Make: Perkins

 Job Number 4
Customer: European Union (EU)

Address: IMAT

Job Type: service

Job Details: service was done on two different generators; changing of oil, oil and fuel filter, cleaning of
generator set, topping of coolant and checking of belt tension.

Generator Power Ratings: 150 KVA and 60 KVA

Generator Makes: Perkins

Engine Makes: Perkins

Day 4 (7/08/2020)
Job Number 1
Customer: Hassan

Address: Signal Hill

Job Type: Service

Job Detail: changing of oil, fuel filter and oil filter and cleaning of generator set

Generator Power Rating: 16 KVA

Generator Make: Stamford

Engine Make: Perkins

Job Number 2
Customer: World Food Program (WFP)

Address: Kissy Duck yard

Job type: service

Job Details: service was done on two generators. Work include changing of oil, changing of oil filter and
fuel filter and cleaning of the generator sets.

Generator Power Rating: 20 KVA and 45 KVA

Generator Make: Coelmo

Engine Make: Perkins

Day 5 (8/8/2020)
Job Number 1
Customer: Besto Foam Manufacturer

Address: Calaba Town

Job Type: Installaion

Job Details: there was a call out for the alternator not being able to charge the battery. On site we
discovered that the alternator belt (separate from the fan belt) was slack and one of the battery
terminals was fouling as well. We changed the belt and tensioned it and also change the battery
terminal and the battery started charging upon starting the generator without changing the alternator.

Generator Power rating: 350 KVA

Generator Make: FG Wilson

Engine Make: Perkins

Job Number 2
Customer: International Organization for Migration (IOM)

Address: Wilberforce Road, Congo Cross

Job Type: Service

Job Details: we changed the oil, the oil filter, the fuel filter and the Air filter, we cleaned the generator
set and primed the filter.

Generator size: 80 KVA

Generator Make: FG Wilson

Engine Make: Perkins

Nature of the Job

The service job includes changing of oil, filters, cleaning of the generator set, reading and recording of
coolant level, belt tensioning, engine RPM, AC alternator line voltages and current out puts, coolant
temperature, oil pressure, DC alternator voltage and charging status, etc.

Before service is commenced, if the engine is cool you first start the engine and allow it to run for few
minutes on idle for the engine to warm up. The engine is then shut-off, remove from auto start, battery
switch turned off and sometimes remove battery terminal. The oil might be properly warmed at this
time for effective draining. After all of these the oil top cover is removed, the dipstick removed and the
oil drain plug can now be opened and the oil will be drained in a container with so much care to avoid oil
spillage on the surrounding floor.

Whiles the oil will be draining the fuel and air filters can be replaced in the process and the oil filter will
be replaced when the burned oil is been drained. The oil plug is lock back in its position and the new oil
is being filled in the engine using the dip stick to indicate full oil. When the dipstick has indicated full oil
the engine will be started and stopped, then the oil is being dipped again to check oil level which will
indicate if there is need or not for a refill.

The generator’s canopy and its floor is being cleaned in the process of dust and the oil that would have
been spilled during the draining process.

The oil will be put into a container provided by the contact person and the replaced filters are left with
the customers except in the case of the service done for WFP where the contact person said he does not
has place to store the replaced filters so we have to go with it and find a place to dispose of it.

The job report form is then filled by recording the generator information displayed on the control panel
in addition to the service being done and information concerning the coolant level and belt tension. The
customer can now sign if pleased with the components used and the work being done.

Skills gained/ improved

As I worked in the service team in my first week as an intern with the Integrated Power and Control
Solution company, I was able to make some improvement to the service skills that I gained during my
internship with Mantrac, refreshed my memory of some that I was about to forget and as well gained
some new ones. These skills are highlighted below:

 Installation of DC alternator and tensioning of fan belt and separate alternator belt
 Draining of oil
 Removal and installation of filters including oil, fuel and air filters
 Reading of engine information on control panel
 Starting and stopping of generator
 Basic troubleshooting of cause for battery not charging

Observations
Below are listed the things that I observed

 One of the 20 KVA generators in the German embassy was having oily liquid around the AC
alternator and the control panel as well. The contact person who is in charge of the generators 88
asked the technicians for the cause and he was somehow disturbed by the problem because he said
that his boss usually goes into the generator house and he has severally asked him for the cause of
the effect but he could not give him answer.
 In some cases I saw the air filters not being changed because according to the visual inspection of
the technician, they are not too dirty so it was not necessary to change the filter
 Oil and fuel filters being pre-filled before installation without taking caution to avoid the oil or fuel
passing through the center hole where the clean oil or fuel will be stored after filtration
 The canopy of the 60 KVA generator with a Lovol engine at Charms Beach Hotel, Aberdeen has
started developing rust. The contact person for the customer asked the technician for solution to
the problem. He was dissatisfied with the fact that it seems like there is no solution to a problem he
desperately wants solution for.
Also, the 20 KVA Leega generator with Perkins engine at Skai Kay’s resident, Goderich has got tea
stain on the power cable ring and screws where it is connected to the AC alternator (it is outside the
canopy).
 Cleaning has always been well done
 The changed oil is handled well to prevent spillage
 There has also been good relationship between the contact person and us the technicians and there
has been customer satisfaction in all the places we have worked

Analysis
The oily liquid around the AC alternator of the 20 KVA Perkins engine at the German Embassy according
to study, the only effect that can be related to that is an effect called “Wet-Stacking”. The Wet-Staking
effect is caused by excessive running of the generator with low or no load. According to Dany Maalouf,
lead consultant, data center engineering services, wet stacking was originally described as a condition in
diesel engines where thick dark substances start dripping from the exhaust system. Stacks are the soots
formed by diesel combustion and accumulated in the exhaust system which when mixed with the
condensed unburnt diesel vapor forms a stack oily liquid and become wet stacking engine. Wet stacking
has an effect on injector nozzles, piston rings, valve seats, etc, which will lead to low engine
performance, expensive engine repair and short engine- life.

The purpose of filters on engines is to prevent unwanted tiny particles that may be deposited in the
fluids from entering the engine because these particles has the potential to cause severe damages to
major internal engine components leading to short engine life and expensive engine repair. So any fluid
entering the filter has to pass through the smaller holes were the fluid is filtered before going to the
center hole. The fluid that is to be in the center hole should be a filtered one from where it will go
straight to the other engine components. Hence if during prefilling, fuel or oil enters through the center
hole into the filter then you will be introducing unwanted micron particles in the small unfiltered oil or
fuel into the engine that will start causing micro damages to the engine and definitely lead to major
engine failures in the future. If this is the normal practice of the technician then it is likely that the
engine life will reduce by a significant percentage.

For the rust forming on the canopies of those two generators mentioned in my observations, is as a
result of proximity with the sea; they are located on beach areas. These happens because salt spray
from breaking waves and onshore wind accelerates corrosion of metals in coastal environment. The
ocean salt which is primarily sodium chloride including other compounds accumulate on the metal
surfaces and accelerate the electrochemical reaction which causes rusting and other forms of corrosion.
These generators are new ones so having the canopies deteriorating at these early stage can cause
customer dissatisfaction; even though it is caused by a natural phenomenon.

Recommendations
Base on my observations, I have few recommendations to make which are subject to review.

 I know most of the time technicians are afraid of getting an air lock after changing the fuel filters so
the try to pre fill the filter before installation. As I mentioned in my analysis, the problem is not with
the prefilling. If you have to prefill then you must take caution not to get fuel through the center
hole. But since it can be hard to prevent that, it is recommended to install the filter dry and prime it
electronically or with the primer lever as the case maybe before starting the engine. Also it is
recommended to install the oil filter dry and when the engine starts the oil pump will send oil in to
the filter in just few seconds
 For the wet stacking effect on the German embassy generator, something has to be done about it
because the customer is dissatisfy with the condition. As a solution I have learned from research, I
recommend that an electrician should be sent there and allow the generator to run on a load of
about 70% to help get the exhaust wormed up to its required temperature. When the generator
runs under its required load it will get to its required temperature which will help to dry up the oily
liquid in the exhaust pipe and blow out the dry soot. If the customer does not has the required load
then a load bank will be needed. Apart from the customer dissatisfaction, the condition will have a
very bad effect on the generator that the company will not want to happen.
 If possible I recommend that special canopies are to be prepared by company for generators that
have to be installed in beach areas. These canopies will have to be first primed with anti-rust
primers before praying them with the generator’s color.

Question
I have made recommendations on issues that I have clear understanding on, but I have one that I don’t
have any clear standing on so I will like to ask questions about it. It’s concerning the air filter.

 Is replacing the air filter for Perkins engines not part of the service schedule?
 If it is, in changing the air filter element, between the service schedule and the dirtiness of the
element, which one should be foremost to consider